Process of making water-impervious concrete



Patented Dec. 20, 1949 UNITED STATES (J a I provide a composition e odying a cement binder sand and a egates commonly used the pregaration o concre rrazzo and mortar and an inert substance and then mixing said composition with water and placing the same in forms or applyifi'g Tfie same to floors, pave-- merits, roads, airfield runways, ornamental structures, wallboard, artificial stone, etc. as the case may be for hardening or setting .and

thereafter applying a suitable solvent for the inert subst'ifib'fiffi' sur ac o e ar en ure an ere "the inert substance to permeate and difiuse completely throughout the pores, crevices, fissures, bubbles and all existing voids and spaces within the hardened mass and between the various materials comprising the same whereby to bring about the permanently sealing oi such voids and spaces to the penetration or absorption of water or water vapor. Portable objects made by this process may be immersed for predetermined period of penetration, in such a solvent, then lifted for drainage and drying.

A further object of my invention is to provide a concrete or like material which will be comparatively inexpensive to mix and lay, one which can be handled by the ordinary workman, and one which will possess the desired qualities of withstanding trailic and having somewhat the appearance of being resilient and warm, and one which can be effectively polished or ground to a smooth finish by an ordinary sand or like abrasive polishing machine.

With these and other objects in view, the invention consists in the combining of certain materials and process of forming a concrete or like article from such materials.

In accordance with my process, I employ the usual materials used in forming concrete, terrazzo or mortar, namely a cement binder, sand, and aggregates, an inert substance such as a wagr insoluble resin. b The cement e r referred to can be an -a inorganic settafie ingredient such as a hydraulic,

Portland, natural or r of Paris, calcium. sulphate,

gsum, aplasFE a caumbinemoramag CROSS Emirate:

PROCESS OF MAKING WATER- IMPERVIOUS CONCRETE Roy 0. Faulwetter, Milwaukee, Wis.

' No Drawing. Application July 9, 1945,

Serial No. 604,095

.qclaims. (01.11176 /'L :5

5 able binder.

15 amount of water is a e go same goesppt begome difluse ulose organic and r anic esters, 40 Iulose etfiers, and the El e.

The natural rosin, was or gum, is meant to Sam PATENT OFFICE. t S 7 7 nesium oxychloride or other magnesium or magnesite or ox sa composition; or any other aeraj e iaBIefL.ma te u s ance. 81mm? mass set out above which may serve as a suit- The aggregate used can be m Fv bbles, marblechips, sawdust, cinders' as as mica, ic, Hint, or manufactured particles such as powdered ceramic material; or any other par- 10 ticles which serve as an extender, a diluent or filler, regardless of size of such particles.

with this concrete, mortar or terrazzo mixture, is incorporated a desired powdered dry inert material or lastic resin. The desired M e mixture so that the mixture can be spread on a surface or cast into suitable forms. At this point, it is to be noted that while the inertmaterial or resin is distributed throughmTFtHEamEi-e. e til the mixture has set or hardened aififiih tr eateg withg certain chemical or chemical compoun e"inert ma erial used can be either a synthetic plastic resififnatural rosin, wax or gum; af

ill 8. ry DOW ere orm.

By e rm syn group of or anic and'for'sili "e chemical sub-' stances wHicH may be manufactured by a comation or synthesis of previously manufactured 30 substances and which products may be procured razaoas 'broughfloht above. As 'eifollowing can be mentioned:

n ii on nd co ol rs, l e ene dr c ron resins, or a o ers, ce-

include the fitireiroup of soluble (in suitable solvent for each separate substance) products of nature, such as ine rosin, chicle, mastic, balcarnau a wax procured from Edie dates, sa or distillationmtxegm,

mafiri'als, and a o lac beeswax, gelatin pro- 55 on a surface and then troweled or spread to form a plane face. When the mass has hardened, (i. e., when chemical hydration has occurred and l minous cement; or aa large percentage of the residual water has evaporated) then the same is thoroughly wet with a penetrating material or materials,

etic resin is meant that "3 351mm of the type of synthetic resin used, the

cured from animal ma er, or Ito cuma one-- indene res'iiis' 'efi "obtam' ed petroleum, 50 s Bait and other soluble in water or water in.

d as well as solvents for the plastic ma ticizers may be diluted with either t e s 3 called glvgpt and/or plasticizer, which will i s cgve the lastic resin or ert material to ra e tlflatterto du's'ifigfieifiegggmcffgu: fit'filth'bp'emngs, vTfids an'dfissures within the hardened mass. This is accomplished either by pouring the material upon the hardened floor, pavement, or runway, or by immersing portable products in such material.

The set concrete is treated with the solvent and/or solvent-type plastieimer f or tl e par{iii 1511a; kind of resinous matefla'fused until the resinous rzsieflarefiter's" into soiiitfd'n throughout the concrete mass to eliminate voids therein.

This also permits the plastic solution to spread over the surface of the hardened mass, thus producing a smooth velvety surface.

This treatment with the solvent and/or plasticizer permits the latter to penetrate the mass "concrete and wet the inert plastic resin or natural rosin, gum or wax which has been introduced with the cement itself, and which up to this point has remained as an inert element in the mixing and setting of the concrete. Upon contact of the solvent and/or plasticizer, the resin particles become wet, swell and enter the earlier stages of solution. This dissolving process continues so long as the solvent and/or plasticizer remains in contact with the resin, and the resultant solution eventually diffuses throughout any voids, however minute or microscopic they may be. A As an example of the chemical used, the follow- .ing can be mentioned:

Di- 2-ethylhexyl phthalate, dioct l hthalate," pmmmthyifiexoafefl trires I Hos hate ethylhexyl Htfialate, orm fiEe, preierabIy suchm evaporation rates under normal conditions and are least These three substances function as plasticizers terial e: ferred in maternal below.

The amount of solvent and/or plasticizer required is determined by the rate of and volume of the absorption thereof.

In order to accelerate penetration, the plasolvents for the s thetl esins used, such as met by! IE"- Butyl Eet one, methyi ethyl ketone and he like" i'or the vifiyl and certain other 'r'esins, various aceti acid esters for cellulose derivatives; ben- 'zene,

nastha turpentin for the natural rm gums an waxes.

As a diluent, and at the same time increasing penetrating properties, the plasticizers such as tricresyl phosphate," etc., may be combined with a modiil romatic na tha.

The following proportions of materials have ixture, which may be sanded or ru e an been found advantageous for typical terrazzo type polished with abrasive paper or cloth applied dry to expose the particular aggregate used and render an exceptionally smooth surface:

Pounds Aggregates (dolomite, screened to pass 4 mesh and re a ed on mesh sieves) 167 Vinyl acetate-chloride copolymer 7.5 Portland cement 94 Gazing water (4% gal. per sack) 37.3

1 =3 isrsin aent can in the above mixture to increase isper- Aggregates (dolomite screened to pass mesh and retained on 10 mesh sieve) 177 Vinyl acetate-chloride copolymer A sulphonated wettin agent g and dispersing Pounds 4 Water When this mixture ha preferably treated with polyethylene glycol di-2- s been laid, the same is a ,solxentnconsisting of vomit-emanatesrparrty'vammef' increase hydration particles in lieu of t dispersing agent me agent in dry form m Any preferred we minute amounts to and fiOCCUIS-EIOH of the cement he sulphonated wetting and ntioned above; or a wetting ay be added to the dry cement ttin a ent may be added in a n water in order to and aggregate mixture to accomplish the same result.

It shall be a definite to incorporate the ve water possible for s part of these formulations ry smallest amount of gaging atisfactory spreading, screenamount required chemical reactions while prevent as much setting and to reduce the amount trained air in the hardened mixture.

In the above formula, crushed marble o chips may be used in place of 49 tioned in order to obtain the combinations recognized in su faces.

Another variation of the ab of contained or enr ranite T 15 distinctive color ch terrazzo surove would be to use aggregate material of flger ggegging such as we sieves, with other mately the same.

of the Such a mixt greater tensile strength in rela or pavement topping.

A typical formula for use as a pavement, road or follows pass 0 mesh and be retained '55" 35 mesh ingredients remaining approxiure would supply tion to thickness mass and greater cross-shear or load bearing strength when spread in a relatively thin floor "topping: for a air field runway would be as Screened sand 2% to 3 parts by volume Portland l6 flooded with solve cement, 1 part by volume y ace tE-cjilgride co weight of cen'ient'fised A sulphinated wetting and diggers y weigh o cenfeiit used Kate 4 gallons per sac moisture in sand used. M.-

After setting and dr polymer, 3% to 10% by peri ee?- 1% k of cement, including ying, the surface to be and/or lasticizer, with or without addition of penetrating dfiuent.

Same alternative s to secure assessments hydration and flocculation of the cement particles may be used as the t e519, added to th mortar or terrazzo the amount of ce 76 and to the normal mentioned above. In general it may be said that the proportion of sehireli asia aura or ma be dry ingredients of the cbncrete,

mixture shall be in relation to ment or cementing substance porosity of the hardened mass ethylhexoate 4 parts by REFiiiitiiUi:

after the addition of water and resulting setting obtained of the same.

While I have gone into some detail, it is to be understood that I do not wish to limit myself to the exact proportions of the materials listed above or to the exact materials or chemicals used, and that, obviously, equivalents of such materials can be used without departing from the spirit or the scope of my invention, but what I claim as new is:

1. The process that includes the addition of dry solid particles of water insoluble but otherwise soluble resinous material in a concrete mixture which comprises hydraulic cement, stone particles and water, said resinous material being in the proportion of 3% to by weight of the hydraulic cement used, said resinous material being inert relative to the hydraulic cement, allowing the mixture to set and harden and then contacting the surface of the set concrete with a solvent for said resinous material and continuing said contact until the resinous material has entered into solution and until the voids in said concrete have been filled, and finally allowing the solvent to evaporate to solidify the resinous material.

2. The process that includes the addition of dry solid particles of water-insoluble but otherwise soluble resinous material in a concrete mixture which comprises hydraulic cement, stone particles and water; said resinous material being in the proportion of 3% to 10% by weight of the hydraulic cement used, said resinous material being inert relative to the hydraulic cement, allowing the mixture to set and harden and then contacting the surface of the set concrete with a solvent-type plasticizer for said resinous material and continuing said contact until the solvent-type plasticizer permeates the concrete mass and until the resinous material has entered into solution and until the voids in said concrete have been filled, and finally allowing the solvent-type plasticizer to evaporate to solidify the resinous material.

3. The process that includes the addition of dry solid particles of water-insoluble but otherwise soiuble resinous material in a concrete mixture which comprises hydraulic cement, stone particles and water; said resinous material being in the proportion of 3% to 10% by weight of the hydraulic cement used, said resinous material being inert relative to the hydraulic cement, allowing the mixture to set and harden and then contacting the set mixture with a solvent and a solvent-type plasticizer for said resinous material, and continuing said contact until the resinous material has entered into solution and until the voids in said concrete have been filled, and finally allowing the solvent and the solventtype plasticizer to evaporate to solidify the resinous material.

4. The process that includes the addition of dry solid particles of resinous material, namely, vinyl acetate-vinyl chloride copolymer in a concrete mixture which comprises hydraulic cement, stone particles and water; said vinyl acetate-vinyl chloride copolymer being in the proportion of 3% to 10% by weight of the cement used. said copolymer resin being inert relative to the hydraulic cement, allowing the mixture to set and harden and then contacting the surface of the set concrete with a solvent for said copolymer resin and continuing said contact until the copolymer 6 resin has entered into solution and until the voids in said concrete have been filled, and finally allowing the solvent to evaporate to solidify the resinous material.

5. The process that includes the addition of dry solid particles of resinous material, namely, vinyl acetate-vinyl chloride copolymer in a concrete mixture which comprises hydraulic cement, stone particles and water; said vinyl acetate-vinyl chloride copolymer being in the proportion of 3% to 10% by weight of the cement used, said copolymer resin being inert relative to the hydraulic cement, allowing the mixture to set and harden, and then contacting the surface of the set concrete with methyl isobutyl ketone and continuing said contact until the copolymer resin has entered into solution and until the voids in said concrete have been filled, and finally allowing the methyl isobutyl ketone to evaporate to solidify the copolymer resin.

6. The process that includes the addition of dry solid particles of resinous material, namely, vinyl acetate-vinyl chloride copolymer in a concrete mixture which comprises hydraulic cement, stone particles and water; said vinyl acetate-vinyl chloride copolymer being in the proportion of 3% to 10% by weight of the cement used, said 00- polymer resin being inert relative to the hydraulic cement, allowin the mixture to set and harden and then contacting the surface of the set concrete with a solvent-type plasticizer such as polyethylene glycol di-2-ethylhexoate, and continuing said contact until the copolymer resin has entered into solution and until the voids in said concrete have been filled.

7. The process that includes the addition of dry solid particles of resinous material, namely, vinyl acetate-vinyl chloride copolymer in a concrete mixture which comprises hydraulic cement, stone particles and water; said vinyl acetate-vinyl chloride copolymer being in the proportion of 3% to 10% by weight of the cement used, said copolymer resin being inert relative to the hydraulic cement, allowing the mixture to set and harden, and then contacting the surface of the set concrete with a mixture of a solvent and a solvent-type plasticizer for said copolymer resin, namely, methyl isobutyl ketone and polyethylene glycol di-2-ethylhexoate, and continuing said contact until the copolymer resin has entered into solution and until the voids in said concrete have been filled, and finally allowing the solvent to evaporate.

ROY C. FAULWE'I'IER.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,034,324 Thoma July 30, 1912 1,331,217 Schutte Feb. 17,1920 1,521,813 Hornstein Jan. 6, 1925/0643;- 2,040,320 Lovell May 12, 1936 FOREIGN PATENTS Number Country Date 124,669 Great Britain 1919 202,785 Switzerland 1939 1 682,857 Germany 1939 EXIiFviiNER 

